Introduction - ENGINE

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage.

Closely observe the following precautions when carrying out operations in the engine compartment.

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that an extinguisher is at hand in the work area.

For some procedures, the use of special Fiat tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/1992).

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• turn off the engine and wait for it to cool down
• do not smoke
• do not use naked flames
• make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user.

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Closely observe the following precautions when carrying out operations in the engine compartment.

• Turn off the engine and wait for it to cool down.
• Do not smoke.
• Do not use naked flames.
• Make sure that there is an extinguisher at hand in the workplace.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with M.D. no. 47/1992).

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage.

Closely observe the following precautions when carrying out operations in the engine compartment.

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that an extinguisher is at hand in the work area.

For some procedures, the use of special Fiat tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/1992).

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• turn off the engine and wait for it to cool down
• do not smoke.
• no naked flames
• Make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give the user.

BIPOWER

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Closely observe the following precautions when carrying out operations in the engine compartment.

• Turn off the engine and wait for it to cool down.
• Do not smoke.
• Do not use naked flames.
• Make sure that there is an extinguisher at hand in the workplace.

For some procedures, the use of special Fiat tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with M.D. no. 47/1992).

All versions

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage.

Closely observe the following precautions when carrying out operations in the engine compartment.

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that an extinguisher is at hand in the work area.

For some procedures, the use of special Fiat tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/1992).

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• turn off the engine and wait for it to cool down
• do not smoke
• do not use naked flames
• make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user.

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Closely observe the following precautions when carrying out operations in the engine compartment.

• Turn off the engine and wait for it to cool down.
• Do not smoke.
• Do not use naked flames.
• Make sure that there is an extinguisher at hand in the workplace.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with M.D. no. 47/1992).

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage.

Closely observe the following precautions when carrying out operations in the engine compartment.

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that an extinguisher is at hand in the work area.

For some procedures, the use of special Fiat tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/1992).

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• turn off the engine and wait for it to cool down
• do not smoke.
• no naked flames
• Make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give the user.

To connect SL quick-release fittings, push the fitting fully home and then pull to check the pipe is secure without touching the tabs on the outer case of the female quick-release fitting.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, apply gentle blows using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation. When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.

When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Whenever you dismantle the high pressure pipes within the fuel system:

• fuel manifold/injector pipe
• pipe between high pressure pump/fuel manifold, replace by ordering new pipes from Parts.

To connect SL quick-release fittings, push the fitting fully home and then pull to check the pipe is secure without touching the tabs on the outer case of the female quick-release fitting.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.

All the operations must be carried out with the utmost attention and care to avoid damaging the components.

Before any interventions on electrical components, including battery disconnection, make sure that the ignition is off ('STOP position).

In order to release parts which are sticking, tap lightly using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

During dismantling, check that parts which have to be marked carry reference marks.

When refitting, lubricate the parts, where necessary, to prevent sticking or seizing during the initial operating period. During refitting, it is essential to observe the tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Whenever you dismantle the high pressure pipes within the fuel system:

• fuel manifold/injector pipe
• pipe between high pressure pump/fuel manifold, replace by ordering new pipes from Parts.

The rapid connectors for the fuel pipes are the JOHN GUEST and GSL types.

To prevent fuel vapour leaks, the quick-release fittings are fitted with two interior O-ring seals.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.

BIPOWER

All the operations should be carried out taking great care not to damage the components.

Do not start up the engine when the terminals for the electrical connections are not properly connected or are slack at the battery poles.

In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.

When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts and all components which have deteriorated.

Before removing-refitting any of the CNG system components, observe the safety and system drainage regulations in the relevant procedures.

Personnel should follow all regulations in force and take care to observe all safety recommendations. Below is a list of instructions which must, under all circumstances, be observed during any operations on vehicles equipped with LPG systems.

In particular, when opening the connectors or moving pressurized components, operators should wear a helmet with a visor which conforms to regulation UNI-EN 166 for protecting their face from any jets.

The system adopted on the Doblò bipower conforms to the regulations in the individual countries where it is marketed.

The presence of two one-way valves prevents accidental emergence of gas from the cylinders.

Fuor solenoid valves are present (one solenoid for the cylinder and one on the pressure reduction unit) which isolate the two sections of the supply pipe when the supply is selected in petrol mode or when the engine is switched off.

A manual methane cut out tap is located on each solenoid. Its opening/closure permits or prevents the exit or entry of methane from the canister. Although the methane system has many safety features, you are advised to shut off the manual cock of each individual cylinder whenever the vehicle is garaged for a long period, transported on other means of transport or handled in emergency situations caused by faults or accidents.

In spite of the presence of these devices it is necessary to remember that, in ambient conditions, methane is a highly flammable gas; in the presence of potential leaks during maintenance operations to the system, always follow these precautions:

• do not smoke
• no naked flames;
• do not use electric tools and driers.
• do not use incandescent lamps;
• do not wear acryclic clothes which produce static electricity;
• always disconnect battery terminals.
• do not use workshop equipment such as: air compressors, current generators, exhaust fans, electric tools, etc. which could produce sparks and, if there were leaks, cause an explosion.
• do not use any type of exhaust fan;
• always work in well ventilated areas.
• vehicles with methane gas systems which have been in an accident or those where the seal of the system may not be intact should not be kept is sealed environments.

The Doblò bipower is fitted with a high-pressure methane system, designed to operate at a nominal pressure of 200 bar. It is dangerous to force the system with higher pressures. Do not change the configuration or components of the methane system; they have been designed exclusively for the Doblò bipower. The use of other components or materials could cause malfunctions and adversely affect safety. If the vehicle is placed in a drying oven after painting, at temperatures above 80° C, the methane cylinders must be removed from the vehicle.

After having removed one or more of the CNG high or low pressure system components, carry out a search for leaks, using the leak detector equipment or, alternatively, a foam solution, and repair any damaged components.

All versions

To connect SL quick-release fittings, push the fitting fully home and then pull to check the pipe is secure without touching the tabs on the outer case of the female quick-release fitting.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, apply gentle blows using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation. When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.

When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Whenever you dismantle the high pressure pipes within the fuel system:

• fuel manifold/injector pipe
• pipe between high pressure pump/fuel manifold, replace by ordering new pipes from Parts.

To connect SL quick-release fittings, push the fitting fully home and then pull to check the pipe is secure without touching the tabs on the outer case of the female quick-release fitting.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.

All the operations must be carried out with the utmost attention and care to avoid damaging the components.

Before any interventions on electrical components, including battery disconnection, make sure that the ignition is off ('STOP position).

In order to release parts which are sticking, tap lightly using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

During dismantling, check that parts which have to be marked carry reference marks.

When refitting, lubricate the parts, where necessary, to prevent sticking or seizing during the initial operating period. During refitting, it is essential to observe the tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Whenever you dismantle the high pressure pipes within the fuel system:

• fuel manifold/injector pipe
• pipe between high pressure pump/fuel manifold, replace by ordering new pipes from Parts.

The rapid connectors for the fuel pipes are the JOHN GUEST and GSL types.

To prevent fuel vapour leaks, the quick-release fittings are fitted with two interior O-ring seals.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.